Packaging machine

ABSTRACT

Apparatus and method are provided for automatically loading a desired quantity of flat, flexible bags into dispensing cartons which comprises, in combination, a stacker mounted adjacent to and aligned with a completed bag dispenser, said stacker having vibration means for automatically collecting a desired number of completed bags in an aligned stack, means for conveying said aligned stack of bags to a carton loading station, means for depositing a stiffening member over a predetermined portion of said aligned stack of bags, means for folding said stack of bags, means for conveying an empty carton from a continuous conveyor of empty cartons to said carton loading station, and means for automatically folding and stuffing said stack of bags into an empty carton at said carton loading station.

[451 Mar. 12, 1974 PACKAGING MACHINE [75] Inventors: Ronald J. OShea, Somerville; Bernd W. Haase, Berkeley Hts; Albert W. Hawkins, Princeton, all of NJ.

[73] Assignee: Union Carbide Corporation, New

York, N.Y.

[22] Filed: Apr. 17, 1972 [21 Appl, No.: 244,776,

Related US. Application Data [62] Division of Ser. No. 30,069, April 20, 1970, Pat. No. 3,656,27l.

52 use 51 men. ..B65h31/34 [58] Field of Search 271/89; 93/93 C; 214/6 D,

1,280,830 10/1918 Petty 271/89 3,225,942 12/1965 Fossenier ..2l4/6 DK Primary Examiner-Edward A.,Sroka Attorney, Agent, or Firm-Franklyn Schoenberg 57] ABSTRACT Apparatus and method are provided for automatically loading a desired quantity of flat, flexible bags into dispensing cartons which comprises, in combination, a stacker mounted adjacent to and aligned with a completed bag dispenser, said stacker having vibration means for automatically collecting a desired number of completed bags in an aligned stack, means for conveying said aligned stack of bags to a carton loading station, means for depositing a stiffening member over a predetermined portion of said aligned stack of bags, means for folding said stack of bags, means for con-, veying an empty carton from a continuous conveyor of empty cartons to said carton loading station, and means for automatically folding and stuffing said stack of bags into an empty carton at said carton loading station.

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7 i FlG./7 M w vvj PACKAGING MACHINE This is a division of application Ser. No. 30,069 filed Apr. 20, I970 now U.S. Pat. No. 3,656,271.

This invention relates to packaging machines and more particularly relates to apparatus and method for collecting a desired number of flat, flexible bags from a bag forming machine and loading said bags in bagdispensing cartons. The apparatus of this invention is particularly well suited for use with high speed bagforming machines.

An object of this invention is to provide apparatus for automatically arranging completed flat, flexible bags in stacks containing a desired number of bags and loading said bags in cartons, the apparatus being adaptable to vary the quantity and sizes of bags desired to be loaded in the carton.

Another object is to provide in association with a high speed bag-forming machine apparatus to collect and stack in aligned stacks a desired number of completed flat, flexible bags formed by said bag-forming machine and automatically loading said stacks of bags in dispensing cartons.

A further object is to provide apparatus for automatically dispensing a stiffening member from a stack of stiffening members and depositing said stiffening member on a stack of aligned flat, flexible bags.

Other objects of the present invention will become apparent from the following detailed description taken in connection with the accompanying drawing.

It has now been found that the objects of the invention can be generally attained by providing apparatus comprising, in combination, means for automatically collecting and stacking in an aligned stack a desired number of flat, flexible bags; means for conveying said aligned stack of bags to a carton loading station; means for conveying empty cartons to said carton loading station; and means for folding and stuffing said stack of bags into said empty carton. The bags so loaded in the carton may be dispensed from said carton one at a time. i

In one embodiment, the apparatus of the present invention comprises a stacker mounted adjacent to and aligned with a completed bag dispensing means associated with a high speed bag forming machine, said stacker having a wall pivotally mounted with vibration means connected thereto and a pivotally mounted bottom closure whereby completed bags dispensed from a bag-forming machine enter said stacker, and the vibrating wall of said stacker aligns said bags in a stack as they become deposited on the pivotally mounted bottom closure. A reciprocally mounted stack carrier is located immediately below and in vertical alignment with said stacker whereby an aligned stack of a desired number of completed bags are transferred from said stacker to said stack carrier upon opening of the pivotally mounted bottom closure of said stacker. The apparatus also is provided with means for conveying said stack carrier to a stiffening member dispensing station; means for dispensing a stiffening member from a stack of stiffening members and depositing the same on a predetermined portion of said aligned stack of completed bags; and means for concurrently conveying said stack carrier to a carton loading station and folding said stack of bags over the portion of the stack covered by said stiffening member. Also is provided means for conveying an empty carton to said carton loading station from a continuous conveyor of empty cartons said empty carton being stationed immediately below and in vertical alignment with a stuffing chute in said stack carrier; and means for folding and stuffing said folder stack of bags into said empty carton. Upon being filled the carton is conveyed from said' carton loading station and said stack carrier is conveyed back to its station immediately below said, stacker.

The apparatus and method of the present invention will become apparent from the following description thereof when considered together with the accompany ing drawing which is set forth as being exemplary of one embodiment of the present invention and is not intended, in any way, to be limitative thereof and wherein;

FIG. 1 is a side elevation view, part in section and part in phantom, of one embodiment of the apparatus of the present invention in an assembly having four parallel operating embodiments of said apparatus all performing the same function. 7

FIG. 2 is an end elevation view, part in section, of the apparatus of FIG. 1.

FIG. 3 is a plan view, part in section and part in phantom, taken through line 3--3 of FIG. 2, and part in phantom of the apparatus of FIG. 1. I

FIG. 4 is an end elevation view, part broken away, illustrating a collecting and stacking stacker of the apparatus of FIG. 1.

FIG. 5 is a side elevation view taken through line 5-5 of FIG/4 and showing a side elevation view, in section, of a completed bag dispensing mechanism aligned therewith.

FIG. 6 is an enlarged end elevation view, part in section and part in phantom, illustrating the stiffener member dispenser of the four unit assembly of the apparatus of FIG. 1..

FIG. 7 is an enlarged side elevation view, part in section and part in phantom, of the stiffener member dispenser of the apparatus of FIG. 1.

FIG. 8 is an enlarged plan view, part broken away, of the stiffener member dispenser of the apparatus of FIG. 1.

FIG. 9 is an end elevation view taken through line 99 of FIG. 8.

FIG. 10 is a plan view, part in section illustrating a stack carrier of an interior embodiment of the appara tus of FIG. 1.

FIG. 11 is a side elevation view, part in section, taken through line 11-11 of FIG. 10 and showing .the general relationship of a stiffening member being deposited over a portion of a stack of flat, flexible bags.

FIG. 12 is a plan view, part in section, illustrating a stack carrier of an exterior embodiment of the apparatus of FIG. 1.

FIG. 13 is an end elevation view, part in section and part in phantom, taken through line 13-13 of FIG. 12.

FIGS. 14 and 15 are fragmentary end elevation views, part in section, taken through line 13-13 of FIG. 12 illustrating in conjunction with FIG. 13 sequential steps in the loading of an empty carton with a folded stack of bags.

FIG. 16 is a plan view, part in. section and part in phantom, illustrating thecarton shuttle means-conveying cartons to two of the carton filling. stations of the apparatus of FIG. 1.

FIG. 17 is a fragmentary end view, part in section, of the carton shuttle means of the apparatus of FIG. 1.

FIGS. 18 and 19 are fragmentary end views, part in phantom, of an alternate bag stuffing embodiment of the apparatus of the present invention.

Turning now to the drawing, wherein like reference numerals denote like parts, there is shown in FIGS. 1, 2 and 3 a general assembly comprising four packaging machines that operate in concert and incorporate the essential features of this invention. In the packaging machine assembly there is provided a base support frame 10. Stacker 16 is mounted at the collecting or fore end of said frame by brackets not shown in an attitude that would be adjacent to and aligned with completed bag dispenser 14. Stack carrier 23 is secured on carrier guide 21 which is slidably mounted on guide track 21(a). Guide track 21(a) is mounted on said support frame 10 and extends from the fore or collecting end of said frame 10 to the aft or carton stuffing end of said frame 10. The stack carrier assembly shown generally as 22 is reciprocally transported over the predetermined path set out by guide track 21(a) by engagement with drive chain 12 that is propelled by motor 11 mounted on frame 10 and drive chain 13. Support frame 25 is mounted on and above base support frame 10 on which are mounted the stiffening member assembly shown generally as 26, the bag stuffer shown generally as 59 and empty carton feeder shown generally as 70.

Referring now to FIGS. 4 and 5 stacker 16 is shown in an adjacent and aligned position with respect to completed bag dispenser 14 and completed flat, flexible bags 15 are being collected by said stacker l6 and deposited on pivotally mounted bottom closure 18. Wall 17 is secure to pivotally mounted shaft 19 that extends through bushing 19(a). Stacker 16 is shown in FIG. 5 as being mounted on springs 17(a) though a suitable alternative embodiment may include stacker 16 being rigidly mounted. Motor 17(b) supplies vibratory excitation for said pivotally mounted wall 17 and a spring mounted stacker as shown in FIG. 5.

In FIG. 6 is shown the stiffening member dispenser assembly 26 for the four parallel operating packaging machines in a stiffening member dispensing position and, in phantom, in a stiffening member depositing position. In FIG. 7 is shown a side elevation view, part in section and part in phantom, of a single embodiment of the stiffening member dispenser.

Stiffening members 28, as, for example, uniform pieces of cardboard are stacked in container 27 that is mounted on frame 25, said stack of stiffening members resting on tabs 39 located at the bottom of container 27 (FIG. 8).

Engaging the bottom member of the stiffening member stack 28 is vacuum cup 30(a) attached to the end of hollow shaft 30, shaft 30 being mounted perpendicularly from hollow shaft 29. Shaft 29 extends through housing 33 and is rotatably secured therein. Hollow shaft 29 is connected-through hollow pivot 35 to vertically mounted hollow shaft 36 that is slidably secured in sleeve 36(a) whereby a continuous air passage through shafts 36 and 29 extending through shafts 30 to vacuum cups 30(a) is formed.

Cam track 31 (FIG. 7) vertically mounted from frame guides cam roller 32 extending from and pivotally mounted in housing 33 activating rotation of shaft 29 and thereby shaft with vacuum cup 30(a) during the vertical travel of housing 33, said housing 33 being secured to a piston extending from cylinder 34.

In FIGS. 8 and 9 is illustrated a card denester generally shown as 38, the means for separating a single reinforcing member from a stack of said members 28 in container 27 whereby a single reinforcing member can be deposited on the stack of bags being conveyed in stack carrier 22. Cylinder 41 is mounted on plate 40 secured to frame 25. Secured to piston rod 42 is denesting member 43 which is guided by plate 40 under the adjacent wall of container 27 to engage the edge of the bottom member of stack 28. The top surface of the forward edge of member 43 that engages members of stack 28 is notched an amount equivalent to one-half the thickness of a single stiffening member whereby the step formed in forward edge of member 43 engages the bottom member of stack 28 and denests it from other members of the stack.

Referring now to FIGS. 12 to 15, stack carrier shown generally as 22 comprises in an assembly of four parallel operating machines, stack carrier containers 23 the two outside members of which are secured to stack carrier guides 21 that are slidably mounted on stack carrier guides 21(a).

The bottom closure of stack carrier 23 upon which the aligned stack of bags 15 are deposited comprises folding arms and flexible cover 52 supported thereon, said folding arms 50 being secured to pivotal shaft 51 mounted intermediate the bottom portion of said stack carrier 23 extending between the front and rear walls thereof and adjacent to said pivotal shaft is discharge opening 54 between plates 55. Leaf springs 53 are secured to a plate 55 extending over a portion of discharge opening 54.

A reciprocating gear follower 49 is slidably mounted in an upright position on the outside of a wall of stack carrier 23 adjacent to and enmeshed with gear 52(a) secured to the end of shaft 51. Cam roller 48 rotatably mounted at the lower end of reciprocating follower 49 contacts cam track 47 that extends between the stiffening member depositing means 26 to the carton stuffing station 59 (see FIG. 1), the configuration of cam track 47 actuating the reciprocating travel of gear follower 49 and thereby the pivotal travel of shaft 51 and folding arms 50.

Referring now to FIGS. 12 and 13 folding arms 50, cover 52 and a stack of bags 15 are shown in the fold position 'over the portion of bags covered by stiffening member 28 and stuffing arms 60 are in position to stuff said folded stack of bags 15 through discharge opening 54 into vertically aligned empty carton 71.

As shown in FIGS. 1 and 2 stuffing arms 60 are mounted in a vertical position from plate 60(a), in a spaced, aligned relationship, extending downwardly from plate 60(a) in alignment with discharge opening 54 and spacedly aligned between folding arms 50 and cover 52. Plate 60(a) is secured to the end of the piston rod extending from cylinder 61. In the embodiment illustrated in FIGS. 1, 2 and 3 wherein four parallel packaging machines are operating in concert, stuffing arms 60 are provided for at the carton stuffing station for each packaging machine. An alternate embodiment of the carton stuffing means is illustrated in FIGS. 18 and 19 wherein stuffing arm 60 is secured to plate 60(a) downwardly extending therefrom in vertical alignment with discharge opening 54 and spacedly aligned between folding arms not shown. Bracket is secured to stuffing arm 60. Grabbing arm 62 is secured to cam roller bracket 64 that is pivotally mounted on bracket 65 at pivot 66. Cam roller 67 is rotatably secured to bracket 64 at the end opposite the grabbing arm. Cam track 63 is vertically secured at one end to frame downwardly extending therefrom to engage with cam roller 67 and provide track guide therefor. Tension spring 68 is secured between cam roller 67 and member 68(a) horizontally secured through plate 60(a). Tension spring 68 maintains cam roller 67 in contact with cam track 63 and the cam track guides grabbing arm 62 while stuffing bags 15 through discharge opening 54 to empty carton 71.

Referring nowto FIGS. 16 and 17 wherein is illustrated a carton shuttle means for two parallel operating packaging machines that is a component part of the empty carton feeder means shown generally as 70 in FIGS. 1, 2 and 3. Empty carton 71 (FIGS. 1, 2 and 3) is deposited on shuttle plate 76 by chute 72. Shuttle plate 76 is pivotally mounted through pivot 81 to shuttle carrier 77. Shuttle carrier 77 is reciprocally mounted on the horizontally disposed carton shuttle guides 82 and secured at the bottom to carton shuttle drive means shown generally as 75. Carton shuttle guides 82 are mounted on frame 10 and extend from below empty carton chute 72 to below the carton stuffing means 59. Shuttle plate cam roller 80 is mounted under shuttle plate 76 at the leading edge of one end thereof. Cam guide 79 is secured at one end of a bracket the other end of the bracket being secured to frame It), cam guide 79 being inhorizontal alignment with shuttle plate cam roller 80. Tension spring 78 is securedat one end intermediate the leading edge of shuttle plate 76 and at the other end to an arm extending from shuttle carrier 77. As shuttle plate 76 is reciprocally transported by shuttle carrier 77 from the station beneath carton chute 72 (FIG. 1) to the station beneath carton stuffing means 59, shuttle cam roller 80 engages cam guide 79 and shuttle plate 76 is rotated 90" whereby empty carton 71 (FIGS. 1, 2 and 3) trans ported on shuttle plate 76 is in both vertical and axial alignment with discharge opening 54 of stack carrier 23 (see FIG. 13) when the empty carton is deposited at the carton stuffing station. j

A typical operation of a preferred embodiment of the apparatus of the present invention will now be described and will be more readily understood when considered together with FIGS. l-19.

Prior to start up, the fore end of the packaging machine is placed adjacent a completed bag dispenser 14 working in conjunction with one or more bag forming machines, the stacker 16 disposed in horizontal alignment with said bag dispenser 14. The bag dispenser has bag counting means not shown that is electrically coordinated with the automatic cycle control device, not shown, for the packaging machine of the present invention. In normal start position stack carrier 22 is stationed beneath stacker l6, stacker bottom closure 16 is closed, the rod end of air cylinders 34 and 61 are pressurized thus card dispenser shaft and stuffing arms 60 are disposed at the top of their stations. A stack of stiffening members 28 as, for example, a stack of individual pieces of cardboard are placed in container 27 and a continuous line of empty cartons are in place on conveyor '69 with several empty cartons in chute 72. The vibration excitation motor 17('b) (see now shown, is activated.

Bag dispenser 14 is turned on and bags 15 are dispensed into stacker 16 where they are deposited in an aligned stack by the action of pivoting wall 17.'The bag dispensing means 14 may have incorporated therewith an air jet, not shown, to assist in dispensing the bags into stacker 16. When the desired number of bags have been dispensed to stacker 16 the dispenser action is interrupted and the bottom closure 18 of stacker 16 opens depositing the aligned stack of bags in stack carrier container 23. The bottom closure 18 then closes, the bag dispenser starts up again and stack carrier is conveyed to the stiffening member depositing station immediately below the depositing means 26, by drive chain 12 that is activated by motor 11 through drive chain 13. At the stiffening member depositing station motor 11 automatically turns off and vacuum means, not shown, attached to shaft 36, (see FIG. 6) is activated. The head end of air cylinder 41 (see FIG. 9) is pressurized and denester plate 43 engages the edge of the bottom stiffening member in stack 28 urging said member off twoof the supporting tabs 39 (see FIG. 8). The rod end of air cylinder 34 is exhausted and the head end is pressurized activating the vertical downward path of housing 33 and shafts 29 and 30 (see FIGS. 6 and 7). Vacuum cup 30(a) engages the par tially supported bottom stiffening member and conveys it downwardly to be deposited on a portion of the stack of aligned bags in stack carrier 23 (see 'FIG. 11).

The rod end of cylinder 41 is pressurized,the head end being exhausted, and denesting plate 43 withdraws fromthe bottom of container 27. The bottom member of stack-28 having been withdrawn, stack 28 then drops down onto tabs 39. The head end of cylinder 34 is exhausted and the rod end is pressurized activating the reciprocally mounted depositing assembly upwardly to the denesting position (see FIG. 6). Motor 11 again starts up and stack carrier assembly 22 is conveyed to the carton loading station where motor 11 is turned off.

As the stack carrier 22 is being conveyed to the carton loading station cam roller 48 mounted on gear follower 49 (see FIGS. 12 and 13) contacts cam truck 47 and gear follower 49 is urged upwardly and folding arms 50 and cover 52 is rotated to fold the stack of bags 15 over onto the portion of bags covered by stiffening member 28. The folding arms 50 remain in the fold position while the stack carrier 23 rests at the carton loading station.

When the stack carrier 22 is at rest at the carton loading station carton shuttle drive is activated and carton shuttle plate having an empty carton 71 deposited thereon is conveyed to an indexed position immediately below and in vertical and axial alignment with the discharge opening 54 in stack carrier 23 (see FIGS. 12 and 13). Carton shuttle drive 75 is turned off upon carton shuttle plate 76 with empty carton 71 coming to rest at the carton loading station and the rod end of carton stuffing air cylinder 61 is exhausted and the lead end is pressurized.

Stuffing arms 60 are urged downwardly to engage the stack of folded bags 15 in stack carrier 23 and fold and stuff said stack of back through discharge opening 54 into empty carton 71 resting immediately below the discharge opening 54 as is shown sequentially in FIGS. 13, 14 and 15. The rod end of stuffing cylinder 61 is then pressurized while the head end is exhausted urging stuffing arms 60 upwardly, withdnawing them from the stuffed carton and stack carrier 23.

Upon withdrawal of stuffer arms 60, carton shuttle drive 75 is reactivated withdrawing shuttle carriage 77 from the carton loading station and conveying it back to the station under empty carton chute 72 wherein by means, not shown, the filled carton is deposited on a filled carton conveyor 74 (see FIG. 1 and 3), and shuttle plate 76 is ready to receive another carton 71 from chute 72.

Concurrently with the withdrawal of the carton shuttle carriage 77, motor 1 l is activated in a reverse direction and stack carrier assembly 22 is conveyed back to the stacking station immediately below stacker 16 where it is ready to have deposited therein a next stack of aligned bags from stacker 16.

From the foregoing, it will be seen that the present invention provides a packaging machine that is capable of automatically collectinga desired number of flat, flexible bags and then automatically loading said desired number of bags into an empty dispensing carton.

It will be readily appreciated by those skilled in the art that apparatus of this general type are capable of high speed operation, collecting and cartoning stacks of bags at rates as high as 300 per minutes and even higher and the apparatus and method is suitable for use with a variety of sizes of bags or other flat, flexible materials.

What is claimed is:

1. In a machine for automatically collecting a quantity of flat, flexible bags dispensed from a completed bag dispenser in an aligned stack the improvement which comprises a collecting container adjacent to and aligned with said completed bag dispenser said collecting container comprising a pivotally mounted vertically disposed end wall having an upper and lower portion thereof and powered vibratory excitation means secured thereto the upper portion of said end wall being disposed above the dispensing path of said flexible bags, said end wall being adapted to contact bags dispensed from said bag dispenser at a point intermediate said upper and lower portions thereof and a support surface upon which an aligned stack of bags are deposited.

2. The machine of claim 1 which includes in combination means for vibrating said collecting container.

3. The machine of claim 1 wherein the support surface of said collecting container is openable. 

1. In a machine for automatically collecting a quantity of flat, flexible bags dispensed from a completed bag dispenser in an aligned stack the improvement which comprises a collecting container adjacent to and aligned with said completed bag dispenser said collecting container comprising a pivotally mounted vertically disposed end wall having an upper and lower portion thereof and powered vibratory excitation means secured thereto the upper portion of said end wall being disposed above the dispensing path of said flexible bags, said end wall being adapted to contact bags dispensed from said bag dispenser at a point intermediate said upper and lower portions thereof and a support surface upon which an aligned stack of bags are deposited.
 2. The machine of claim 1 which incluDes in combination means for vibrating said collecting container.
 3. The machine of claim 1 wherein the support surface of said collecting container is openable. 